Method for making wheel disks



FOR MAKING WHEEL DISKS ile Patented Sept.- 2, 194'1 UNITED STATES PATENTOFFICE METHOD Foa MAKING WHEEL Disks .George Albert Lyon, Allenhurst, N.J.

Application June 4, 1938, Serial No. 211,782

' 3 Claims.

This invention relates to a method for making wheel disks, and moreparticularly to a novel method for making wheel disks of the type havingan integral folded fastening anges which provides the wheel disk with adouble thickness of metal in that area.

The majority of vehicle wheels of the present day are equipped withornamental wheel disks over their outer surface. The use of these wheeldisks permits the more economical manufacture of vehicle wheels. sincethe wheels themselves may be designed solely for strength and utility-without regard to ornamental appearance, the

wheel disk being employed for the latter purpose. The most popular formof wheel disk at the present time is a disk having a highly polishedexterior surface. In order to minimize the total cost of the wheelassembly, it is, of course, necessary to minimize the cost of the wheeldisk itself as much as possible. The thinner the sheet metal stock iswhich is employed to manufacture the wheel disk, the greater the savingis in the manufacturing costs. It has been found that a wheel disk maybe constructed of asheet of metal stock having a thickness dimension ofsuch a character that if a single thickness of the metal stock isengaged by the resilient wheel disk fastening elements4 on the wheel,the metal of the disk would -be deformed at that point, but which, whenpresented as a double thickness of metal at the point on the diskengaged by the wheel disk fastening elementsthe metal is not deformed.

It is an object of the present invention to pro` vide a novel method formanufacturing wheel disks possessing the above highly desirablecharacteristics.

It is another object of this invention to provide a novel method formanufacturing wheel disks which is extremely economical and whichlprovides a resultingproduct which is rugged and reliable in use.

It is a further object of thepresent invention to provide a novel methodfor manufacturing obliquely axially rearwardly and radially inwardly.

It is a still further object of this invention to gsogside a novelprocess for manufacturing wheel The novel features which I believe to becharacteristic of my invention are set forth with particularity on theappended claims. My invention itself, however, both as to itsorganization, manner of construction, and method of operation, togetherwith further objects and advantages thereof,.may best be understood byreference to the following description, taken in connection with theaccompanying drawings, in which:

Figure 1 is a cross-sectional elevational view of a die-press in which aflat sheet of metal stock is placed;

Figure 2 is a cross-sectional elevational view of the die-press ofFigure 1 showing the initial shape which the sheet metal stock is givenin this press;

Figure 3 is a cross-sectional elevational view of a second die-press,showing the metal article as it has been formed'in the press of Figures1 and 2 mounted therein for the second step of the process; j Y

Figure 4 is a view similar to Figure 3 showing the various elements ofthe press and the metal stock at the conclusion of the forming operationin this press;

Figure 5 is a fragmentary cross-sectional elevational view of a portionof a die-press in which the third step of the novel process is carriedout; and

Figure 6 is a view similar to Figure 5 showing the various elements ofthe press and the metal stock as it appears after the forming operationin this press.

In the various figures of the drawings, I have illustrated a method ofand an apparatus for forming an integral folded fastening flange in aWheel disk structure which provides the wheel disk with a doublethickness of metal Where it is engaged by the resilient wheel diskretaining elements of the wheel. In this instance,'the disk structure isof the type that overlies the outer side surface of the vehicle wheel,beingv held inv position upon the wheel-by resilient wheel diskretaining elements mounted on and carried by the body part of the wheel,and the outer periphery of the disk falls within the outercircumferential edge o f the tire rim.

The apparatus illustrated in Figures 1 and 2 of the drawings is adie-press whichv includes a lower die or die-block I0 having its uppersurface shaped as at II to give the desired initial configuration to apiece of sheet metal stock I2.

'I'he mechanism also includes an upper die I3 carrying a centraldepending die portion I4 complemental in character to the die II of thedie block I3. Spaced from the central die part I4 is a depending fixedring I5. In the space between this ring I and the die part I4 isareciprocable hold down ring I6, which is normally urged downwardly byla plurality of springs I1, or the equivalent, each of which is seated inconfronting recesses I8 and I9 in the die I3 and reciprocal hold downring I6 respectively. The downward and outward movement of the hold downring I6 is limited in any suitable manner (not shown). As the die memberI3 is in Figure l, it is shown in a position immediately above the pieceof sheet metal stock I2 with the hold down ring I6 engaging the sheetmetal stock I2 around its outer edge and holding it in desired position.

The sheet metal stock I2 which has been placed in the die press inFigure 1 may be of any suitable material, but is preferably a relativelythin sheet of stainless steel having a slightly resilien-tcharacteristic.

In Figure 2 of the drawings, the upper die member I3 of the pressillustrated in Figure 1 has been moved under -high pressure to itslowermost position. In this position, the sheet of metal stock I2 hasbeen drawn to the shape illustrated in Figure 2, or in other words, tothe shape provided by the die surface I I of the lower die block I0.Specifically, the s heet metal stock I2 now includes a fiat centralportion 20, an annular groove or depressed portion 2l, an annular ringportion 22 and a hold down portion 23. It is -to be noted that the holddown portion 23 is slightly smaller than the hold down portion as shownin Figure l for the reason that the` metal stock as it is drawn to formthe central portion 20, the groove portion 2I and the ring portion 22 ispermitted to slip slightly in the hold down area. The upper die memberI3 of the die press of Figures 1 and 2 is now raised and the metal formI2 is removed therefrom. Thereafter, it Ais reversed and set in a diepress preferably of the character shown in Figure 3. As shown, the diepress in Figure 3 includes a lower die block 24 having an upstandingcentral die portion 25 which terminates in a dome shaped die surface 26.Extending around the'upstanding die portion 25 is a reciprocable holddown ring 21 which is normally urged upwardly by a plurality of springs28 circumferentially spaced about the central die portion 25. Thesprings 28 are preferably seated in confronting recesses 29 and 30 inthe hold down vring 21 and die block 24 respectively. The lowermostposition of the hold down ring 21 is limited by a plurality of stopblocks 3l mounted on the lower die block 24 and spaced between thesprings 28. The upward movement of the hold down ring 21 caused by thebiasing force of the springs 28 is limited in any suitable manner (notshown).

' =The press illustrated in Figure 3 also includes an upper die member32 having a depending die ring 33. The lower surface of the die ring 33includes a fiat hold down portion 34 and a die portion 35, which isprovided with the same configuration as the upper surface of the ringportion 22'of the metal stock.

As the upper die member 32 is lowered, the hold down portion 34 of thedepending die ring 33 engages the hold down portion 23 of the sheetmetal article I2 and the die portion 35 at the same time engages thering 22 to firmly hold 'the outer portion o f the metal article I2 inplace. As the downward movement of the upper die member 32 continues,the metal in the central portion 23 of the metal article I2 is drawnover the domeshaped lower die surface 23 of the die block 25. Thisdownward movement of the upper die member 32 continues until the holddown ring 21 abuts the stop members "3| on the die block base 24. Themetal article I2 now has the configuration as shown in Figure 4 of thedrawings, and the various members of the press at theconclusion of thissecond step of the process are clearly shown in Figure 4.

It will be observed that during the drawing operation in the press shownin Figures 3 and 4, the metal which forms the hold down portion 23 inthe article I 2 has slipped slightly, thus making the width of theannular band which forms the hold down portion 23 slightly less in widththan it was prior to this second forming or drawing operation. v

The upper die member 32 is now raised, and the metal article I2 isremoved from this press and put into a third press for the purpose offorming a double thickness integral folded flange 36 (see Figure 6). Oneform of die press'whlch has been found highly satisfactory for thispurpos'e has been illustrated in Figures 5 and 6 of the drawings, onlythat portion of the press which is essential to a clear understanding ofthe carrying out of this step of the process, however, beingillustrated, in order to simplify the drawings as much as possiblecommensurate with a clear understanding of the invention.

Referring first to Figure 5, the die press which is fragmentarilyillustrated therein includes a lower die block 31 having an upstandingcentral die portion 38. The upstanding central die portion 38 includes afiat central por-tion 39 which does not engage the metal article I2 andan annular die surface 40 which is shaped to have the ring portion 22intimately seated thereon. The die surface 40, however, continuesdownwardly as at 4I, at an oblique angle, and then upward as at 42, at asecond oblique angle, as is clearly shown in the drawings. The obliquelyinclined surfaces 4I and 42 form an annular groove or forming space inwhich the integral depending ange 36 will be formed in a mannerpresently to be described. 'I'he die press illustrated in Figure 5 alsoincludes an upper die member 44 which is provided with -a centraldepending ,die portion 45 complemental in character to the dome-shapedconfiguration of the metal article I2. Spaced from the central die part45 'is a depending fixed ring 46, and in the space between the xed ring46 and die part 45 is a reciprocable hold down ring 41, which isnormally urged downwardly by a plurality of springs 48 or theequivalent, each of which is seated in confronting recesses 43 and 50 inthe die member 44 and the hold down ring 41, respectively. 'I'hedownward movement of the hold down ring 41 is limited by a plurality ofpins 5I each firmly fixed in the stationary ring 46 and having an 'endportion 52 which extends into a suitable recess 53, in the hold downring 41. As the hold down ring 41 is seen in Figure 5, it is in itslowermost or outer position, with the inner horizontal edge of eachrespective slot 53 abutting a pin 5 I 'I'he inner lower corner of thehold down ring 41 is preferably rounded off, as at 54, and the outerlower corner of the depending central die portion 45 is also preferablyrounded of! as at Il.

' wardly under pressure, the metal in the metal part I2 at the junctionpoint of the ring portion 22 and the central dome-shaped portion 20 isrolled or forced downwardly along the inclined surface 4I of the formingspace 43. This progressive unrolling of the metal continues until itabuts the inclined surface 42 of the forming space 43; whereafter, uponcontinueddownward movement of the upper die member 44, the integralfolded fastening ange 36 is completed. as is shown in Figure 6 of thedrawings, with a double thickness of metal pressed tightly together.

Either prior to the insertion of the metal article I2 into the diepress, as shown in Figure 5, or after the metal article has been removedfrom the die press after the forming operation, as shown in Figure 6,the hold down marginal portion 23 is trimmed off.

.The metal article I2, which is now in the form v of a Wheel disk, isnow removed from the die press after its ange forming operation, asshown in Figure 6, and any na1 finishing or polishing steps maythereafter be performed upon it to place it in its final condition foruse on a vehicle wheel.` Due to the fact that there is a folded doublethickness of metal in the fastening flange r36 of the Wheel disk, thewheel disk at this point is capable of withstanding greater forceswithout permanent disforming than it is throughout the remainder of itsarea where there is only a single thickness of metal. 'I'he wheel diskformed by the above described process is ar ranged to be snapped overthe wheel disk retaining elements carried on a vehicle wheel and to beretained on the wheel thereby. Since the wheel disk retaining elementsof a vehicle wheel are relatively stiff, it is clear that an increase instrength of the Wheel disk in its fastening flange portion is not onlydesirable but necessary to prevent any disforming oi the Wheel disk atthis point when relatively thin sheet metal stock has been employed inmaking the disk.

While I have shown particular embodiments of my invention, it will, ofcourse, be understood that YI do not wish to be limited thereto, sincemany modifications may be made, and I, there- I fore, contemplate by theappended claims to cover all such modi'cations as fall within the truespirit and scope of my invention.

I claim as my invention: 1. 'Ihe method of forming a folded flange in acircular member having a crown-like top portion. an outer portion. andan upstanding cylindrlcal side wall connecting said portions, whichincludes: holding said outer portion against wall against a conicalforming surface adjacent said outer portion, which surface extendsobliquely inwardly at an obtuse angle with respect to the side wall, andpositioning a cylindrical guiding surface around said side wall vforrestraining outward collapse of said side wall, thereby to collapse saidside wall obliquely inwardly along said forming surface from they heldouter portion to form an obliquely extending folded flange from the wallbetween the top and outer portions.

2. The method of forming a folded fiange in a circular member having acrown-like top portion, an outer portion, and an upstanding cylindricalside Wall connecting `said portions, said outery portion extending awayfrom said cylindrical wall at an acute angle with respect thereto, whichincludes: holding said outer portion against movement and subjectingsaid crownlike top portion to endwise pressure to force said side Wallagainst av conical forming surface adjacent said outer portion, whichsurface extends obliquely inwardly and at an obtuse angle with respectto the side wall and substantially in line with the outer portion, andpositioning a cylindrical guiding surface around said side wall forrestraining outward collapse of said side wall, thereby to collapse saidside wall obliquely inwardly along said forming surface from the heldouter portion to form an obliquely extending folded iange from the Wallbetween the top and outer portions.

A3. 'I'he method o f forming a foldedv flange in a circular memberhaving a crown-like top portion, an outer portion, and an upstandingcylindrical side wall connecting said portions, which includes holdingsaid outer portion against movement and subjecting said crown-like topportion to endwise pressure to force said side wall against a conicalforming surface adjacent said outer portion, which surface extendsobliquely inwardly and at an obtuse angle with respect to the side wall,positioning a cylindrical guidy GEORGE ALBERT LYON.

